Assignment questions for UNIT-I Metal Casting Processes

PART-A
1. Define the followings(related to Pattern)
a. Pattern b. types of pattern, c. Pattern materials, d.List pattern materials
e. Pattern materials properties, f.Pattern allowances.g.List of pattern allowances
2. Define the followings(related to Molding sand)
a. Components (constituents) of molding sand b. Types of molding sand
c. Properties of molding sand, d. Examples of molding sand e. Requirements of molding sand
f. Types of binding materials g. Tests for molding sands.
3. Define the following (related to molding machine)
a. Functions of molding machines b. Types of molding machines
4. Define the following (related to core)
a. Define core, b. Functions of core, c.Types of core d. Core print, e.Functions of core print
5. What are the advantages and applications of ceramic moulds?
6. What is the function of a blind riser?
7. What are the possible casting defects when the pattern design is poor?
8. What are the ingredients of core sand?
9. Differentiate the terms mold and core.
10. Why are riser provided in molds?
11. List any four types of resin used in shell molding process.
12. List any four defects of castings.
13. List any four products manufactured by centrifugal casting process.
14. What do you mean by active clay?
15. What is use of riser?
16. What is core venting?
17. What is CO2 process of molding making?
18. What are the function of gating and riser?
19. Mention any two merits and demerits of die casting.
20. What is last-wax method?
21. Give any two merits and demerits of investment casting process.
22. What is mean by match plate pattern?
23. How will you calculate the grain fineness number?
24. What are the defects caused by low pouring temperature?
25. How patterns differ from casting?
26. What are the tests carried out to determine the quality of casting?
27. What is meant by split pattern?
28. What is draft allowance? How is it provided for patterns?
29. What is the need of special casting process?.
30. Write short notes on Chills
31. Write the types and functions of risers.
PART-B
1. What are the types of patterns and explain them with suitable sketch .
2. What are the factors which govern the selection of a proper material for pattern making?
3. What are the specific advantages of match plate patterns? Explain how they are used for making mold?
4. Sketch and discuss the uses and advantages of a gated pattern.
5. Discuss the necessity of the various pattern allowances with neat sketches.
6. What is core and explain how to make a core? Explain the various types of cores
7. Discuss the various properties of molding sand.
8. Describe the step involved in the preparation of green sand mold with cope and drag pattern.
9. Describe various materials used for making patterns. What are its merits and demerits?

10. Give the step wise procedure for the shell mould casting process. List the unique advantages of
making casting in shell molding.
11. Give the sequence of steps in die casting of a part in hot chamber process.
12. Briefly explain the different methods for inspection of castings.
13. Distinguish between green sand molding and dry sand molding based on:
1. Preparation 2.Properties 3. Application.
14. What are the constituents of molding sand? Explain the function of binder in molding sand.
15. Generally, high quality products are produced by centrifugal process. State the reason and explain the
process with clear diagram.
16. List out various non-destructive methods used for testing the casting. Explain the radiography test
used for finding the internal defects in casting.
17. Describe the procedure of making casting by the investment casting process and state its application.
List out the advantages, limitations and applications of investment casting.
18. Describe the various defects in castings(diagrams) , reasons and remedial measures in the table form.
19. Explain the working of Cupola furnace with clear diagram and also describe the various chemical
reactions taking place during melting of iron.
20. What are the main difficulties encountered in Cupola operation? Suggest suitable remedies.
21. What are the basic requirements of core sand? How it differs from the molding sand?
22. What is principle of blast furnace?
23. What do you mean by full molding process? What type of pattern is used in full molding process?
Explain and state the advantages of full molding process.
24. What do you mean by hot chamber die casting process? Explain the process with the help of neat
diagram and compare this process with cold chamber die casting process.
25. Briefly explain the carbon dioxide molding process and state two important merits and demerits.
26. Explain the following methods in the inspection of casting.
1. X-ray testing 2.Ultrasonic testing.
27. What is core, State its requirements? List out the types of cores and sketch any two.
28. What do you understand by external hot rears? How they are caused?
29. What are the methods of cleaning castings?
30. Give a brief account of inspection of casting.
31. Enumerate the various methods of inspection of castings for internal and external defects.
Unit-I-Part-A
1 to10
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31
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21 to30
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31 to 40
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41 to 50
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51 to 60
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27
Unit-I-Part-B
1 to10
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3
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9
11
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11 to 20
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27
29
31
2
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8
21 to30
10
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31 to 40
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27
9
29
13
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19
8
41 to 50
10
12
5
16
29
31
22
15
19
30
51 to 60
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4
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10
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15
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21
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27